Patty-forming apparatus with top feed and rotary pump

ABSTRACT

The food product machine with a food supply, a rotary food pump connected to the food supply, a molding mechanism having a mold plate and a knockout drive, and a mold plate reciprocating between a fill and a discharge position. The knockout drive reciprocates a knockout plunger to discharge molded food products from the mold plate, the mold plate being reciprocated between a cavity fill position and a cavity discharge position. The machine includes a manifold connected an outlet of the food pump and having an outlet passageway connected to an inlet of the molding mechanism for filling the cavity of the mold plate. The machine can further include a fill plunger system for increasing the fill pressure of the food mass prior to filling the mold cavities. Plungers extend into the manifold to displace food mass volume and increase the pressure in the manifold.

This application is a continuation of co-pending U.S. patent applicationSer. No. 14/317,872, filed Jun. 27, 2014, which is a continuation ofU.S. patent application Ser. No. 13/187,448, filed Jul. 20, 2011, nowU.S. Pat. No. 8,801,427, issued Aug. 12, 2014, which claims the benefitof U.S. Provisional Application No. 61/366,046, filed Jul. 20, 2010, theentire contents of all are incorporated by reference herein.

BACKGROUND OF THE INVENTION

Increasing use of pre-processed foods, both in homes and in restaurants,has created a continuously growing demand for high-capacity automatedfood processing equipment. That demand is particularly evident withrespect to hamburgers, molded steaks, fish cakes, and other molded foodpatties.

Food processors utilize high-speed molding machines, such as FORMAX®MAXUM700®, F-6™, F-12™, F-19™, F-26™, or F-400™ reciprocating mold plateforming machine, available from Formax, Inc. of Mokena, Ill., U.S.A.,for supplying patties to the fast food industry. High-speed moldingmachines are also described for example in U.S. Pat. Nos. 3,887,964;4,372,008; 4,356,595; 4,821,376; 4,996,743, and 7,255,554.

Although heretofore known FORMAX patty-molding machines have achievedcommercial success and wide industry acceptance, the present inventorshave recognized that needs exist for a forming machine having an evengreater energy efficiency, an even greater durability, and an evengreater duration of maintenance free operation. The present inventorshave recognized that needs exist for an enhanced controllability andability to tune a patty-forming machine for particular food materials tobe processed, for an enhanced effectiveness of a patty-forming machinein producing uniform patties, for an even greater output rate of pattiesfrom a patty-forming machine, for an enhanced convenience for cleaningand maintenance of a patty-forming machine, and for a smoother andquieter patty-forming machine operation.

SUMMARY OF THE INVENTION

The food product forming machine of the invention provides an automatedfood product molding machine capable of producing uniform molded foodproducts, such as food patties, at a high rate of production.

The food product machine has a food supply, a rotary food pump connectedto the food supply, a molding mechanism having a mold plate and aknockout drive, and a mold plate configured to be driven to reciprocatebetween a fill position and a discharge position. The knockout drive isfor reciprocating a knockout plunger to discharge molded food productsfrom a cavity in the mold plate, the mold plate being reciprocated by amold plate drive between a cavity fill position and a cavity dischargeposition. The knockout drive is positioned below the mold plate. Themachine further includes a manifold connected an outlet of the food pumpand having an outlet passageway connected to an inlet of the moldingmechanism for filling the cavity of the mold plate.

In one embodiment the outlet of the food pump is located above the moldplate and an inlet of the pump is located above the mold plate. The foodpump is a positive displacement pump. The pump has two rotors configuredto create a vacuum between the inlet and the outlet when driven torotate for drawing food product to the outlet.

In one embodiment, the rotary food pump has two rotors. Each rotor hasat least two wings and each rotor has an area of rotation that overlapwith the other rotor. The pump has a drive shaft and a driven shaft, thedrive shaft has a drive gear at a first end and one of the rotors at thesecond end, the driven shaft has a driven gear at a first end and theother of the rotors at the second end; the drive and driven gears aremeshed to operate the rotors in sync.

The machine has a pump motor connected to a drive shaft of the rotarypump. The pump motor is a servo rotary actuator.

In one embodiment, the machine has a hopper for holding a supply of foodproduct, and an auger system configured to force food product through anoutlet of the hopper. The auger system has at least a feed screwconfigured to move food product longitudinally forward in the hoppertoward the outlet.

The feed screw is located in the hopper connected to a feed screw driveconfigured to rotate the feed screw. The feed screw is located at thebottom of the hopper. The feed screw is positioned horizontally in thebottom of the hopper and is configured to rotate and drive food producttoward the front of the hopper.

The hopper has an outlet at the front of the hopper. The outlet extendsfrom the floor of the hopper upward at the front of the hopper.

In one embodiment, the outlet extends forward of the main hopper bodyand encloses a forward portion of the feed screw. The outlet has aconnecting section connected to the main hopper body, and a narrowingsection opposite the connecting section.

In one embodiment, the hopper has an opening at the lower rear of thehopper configured to remove the feed screw therethrough for maintenance,and a cap for removably covering the opening; the feed screw journaledto rotate in an opening of the cap.

In one embodiment, the feed screw drive is located outside of the hopperand is axially aligned and connected with a shaft of the feedscrew. Thefeed screw is longitudinally orientated at the bottom of the hopper.

In one embodiment, the auger system has a plurality of feed screwslocated in the hopper. The feed screws are located adjacent to eachother and adjacent to the floor of the hopper.

In one embodiment, the food product forming machine comprises a plungerfill system to assist in filling mold cavities. The plunger fill systemcomprises a pair of plungers which can be lowered into the intakemanifold to provide an increase in fill pressure by displacing apredetermined volume of food mass.

Numerous other advantages and features of the present invention will bebecome readily apparent from the following detailed description of theinvention and the embodiments thereof, from the claims and from theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of the food product forming machine of theinvention;

FIG. 2 is an enlarged side view of a rotary pump and molding mechanismof the food product forming machine taken from FIG. 1;

FIG. 3 is a top view of the machine of FIG. 1 with certain componentsnot shown;

FIG. 4A is a second partial top view of the machine of FIG. 1;

FIG. 4B is a top view of a portion of the auger system taken from FIG.4A;

FIG. 5 is a partial side view of the machine of FIG. 1;

FIG. 6 is a partial top view of the machine of FIG. 1;

FIG. 7 is a rear view of the forming machine of FIG. 1;

FIG. 8 an enlarged partial rear view of the forming machine taken fromFIG. 7;

FIG. 9 is a side view of a portion of the molding mechanism;

FIG. 10 is a side view of a portion of the knockout mechanism;

FIG. 11 is a front view of a portion of the knockout mechanism takenfrom FIG. 3A;

FIG. 12 is a front view of the machine of FIG. 1;

FIG. 13A is a partial top view of the machine of FIG. 1;

FIG. 13B is a second top view of the machine of FIG. 1 with certaincomponents not shown;

FIG. 14A is an inlet side view of the rotary food pump;

FIG. 14B is an outlet side view of the rotary food pump;

FIG. 14C is a perspective view of a rotor from the rotary food pump;

FIG. 14D is a top side view of the rotary food pump;

FIG. 14E is a schematic diagram of a portion of the rotary pump;

FIG. 14F is a wing of the rotor within an within an portion of it areaof operation;

FIG. 15 is a top side view of the rotary pump with the face plateremoved;

FIG. 16 is a bottom side view of the rotary pump with the back plateremoved;

FIG. 17 is a perspective view of a rotary pump motor;

FIG. 18 is a side view of the fill plunger in a depressed position;

FIG. 19 is a side view of the fill plunger in a raised position;

FIG. 20 is a front view of the fill plunger system;

FIG. 21 is a top view of the fill plunger drive system;

FIG. 22 is a front view of the fill plunger drive system;

FIG. 23 is a side view of one embodiment of a breather system;

FIGS. 24a-24d are side views of alternate embodiments of a breathersystem; and

FIG. 25 is a side view of an alternate embodiment forming machine.

DETAILED DESCRIPTION

While this invention is susceptible of embodiment in many differentforms, there are shown in the drawings, and will be described herein indetail, specific embodiments thereof with the understanding that thepresent disclosure is to be considered as an exemplification of theprinciples of the invention and is not intended to limit the inventionto the specific embodiments illustrated.

Machine Overview

The food product forming machine or food patty molding machine 100 isillustrated in FIGS. 1-13. The molding machine 100 includes a machinebase 21, optionally mounted upon a plurality of feet 22, rollers orwheels. The machine base 21 supports the operating mechanism for machine100 and contains electrical actuating systems, and most of the machinecontrols. The machine 100 includes a food supply system 24 for supplyingmoldable food material, such as ground beef, fish, or the like, to theprocessing mechanisms of the machine. A control panel, such as a touchscreen control panel 601, is arranged on a forward end of the machine100.

As generally illustrated in FIGS. 1, 2, 4A-8, the food supply systemincludes an auger system 400 and a hopper 25 that opens into the intakeof a food pump system 300. The food pump system 300 includes at leastone food pump, described in detail hereinafter, that continuously, orintermittently under a pre-selected control scheme controlled by amachine control or controller 23, pump food, under pressure, into amanifold 27 flow-connected to a cyclically operated molding mechanism28. Generally during operation of the machine 100, the pump is forcingfood material under pressure into the intake of manifold 27. Theoperation of the machine is controlled the machine control 23.

In the operation of machine 100, a supply of ground beef or othermoldable food material is deposited into hopper 25 from overhead. Anautomated refill device (not shown) can be used to refill the hopperwhen the supply of food product therein is depleted. At the bottom ofthe hopper 25 is the auger system 400 for moving the food materiallongitudinally of the hopper 25 to the inlet 301 of the food pump system300.

The manifold 27 comprises a system for feeding the food material, stillunder relatively high pressure, into the molding mechanism 28. Moldingmechanism 28 operates on a cyclic basis, first sliding a multi-cavitymold plate 32 into a receiving position over manifold 27 and then awayfrom the manifold to a discharge position aligned with a series of knockout cups 33. When the mold plate 32 is at its discharge position, knockout cups 33 are driven downwardly, discharging hamburgers or othermolded patties from machine 100, as indicated by direction A in FIG. 2.The molded patties are deposited onto a conveyor 460 that is positionedunder the knockout cups 33, to be transported away from the machine 100.

Food Supply System

The food supply system 24 includes the hopper and the auger system 400,as shown in FIGS. 1, 2, 4A-8. The auger system 400 is located at thebottom of the hopper 25. The auger system includes two feed screws 402,404, and two feed screw drive motors 406, 408. The feed screws 402, 404each have a center shaft 410, 412. The center shaft is journaled in andsupported by front and rear feed screw supports 414, 422. The feed screwsupports extend vertically from and attach to the machine base 21. Thefeed screws are located adjacent to one another and extendlongitudinally along the bottom of the hopper. The center shafts areparallel to the bottom 527 of the hopper.

As shown in FIG. 5, the rear 25 c of the hopper has an opening that iscovered by a cap 530. The cap 530 has holes 531 that the feed screwshafts are journaled to rotate therein on bearings. The shafts extendthrough the cap to connect to the motors 406, 408. The rear opening ofthe hopper has a vertical lip 529 a. The back of the cap has a recessedportion 530 a that mates with the lip 529 a. The cap also has anon-recessed portion 530 b that fits into the rear opening.

A hopper outlet 532 is formed to or attached to the front 533 of thehopper 25. A portion of the outlet opening is aligned with the bottomfloor 527 of the hopper and the opening extends upwardly from the floor527. The outlet extend forward of the main hopper body 25 c as shown inFIG. 5. The outlet has a connecting section 534 and a narrowing section535 that narrows to an outlet flange 536 toward the food pump system300. The outlet has a width that is greater than its height. Upper andlower feed screw supports 420, 421 extend from the conical section 535to a bearing head or sleeve 422. The supports 420, 421 are perpendicularto the conical section 535 inside surface and extend therefrom to anelbow 421 a, 421 b and bearing sleeves 422. The front of the shafts 412,410 have a recessed portion 425 that terminates in a conically reducingpoint end 424. The point end 424 extends beyond the bearing sleeves 422.The shafts 410, 412 are journaled to rotate at the front on the recessedportion 425 in the bearing sleeves. As shown in FIG. 3, a front portion404 a of each feed screw is enclosed by the outlet and extends beyondthe main hopper body 25 c.

As shown in detail in FIGS. 5 and 6, the feed screw drive motors 406,408 are mounted to a feed screw drive motor support plate 430 by screws,studs, or bolts 432. The support plate 430 is attached to a supportmount 431 by screws or bolts 434. The support mount 431 is attached tovertical support members 444, 445 by fasteners 446, 447 respectively.The vertical support members 444, 445 extend vertically from the machinebase 21 and are supported thereon. The support mount 431 has a ledge 435defining a recessed area 435 a. The support plate is located in therecessed area 435 a and on the ledge 435. The drive motors, 406, 408 areenclosed by a drive motor housing 440. The drive motor housing 440 isattached to the support plate 430. The motors 406, 408 are axiallyaligned with the corresponding feed screws 402, 404 respectively. Outputshafts 406 a, 408 a are coaxial with the corresponding feed screw shafts410, 412 respectively. The supports hold the feed screw slightly abovethe bottom 527 surface of the hopper 25 to form a small gap 528 betweenthe feed screw and the bottom.

A cap retaining brace 442 is attached by a bolt 441 to the support plate430 and extends forward to contact the cap 530 by a wide member base 443to hold the cap engaged with the hopper 25.

The feed screws 402, 404 are removable from the hopper for service andcleaning. To remove the feed screws 402, 404, the support plate 430 andthe support mount 431 are disconnected from the vertical support members444, 445 via the fasteners 446, 447. The support mount 431 is movedlongitudinally rearward and the recessed portions 425 of the feed screwshaft are withdrawn from the bearing sleeves 422 at the front and thefeed screws are withdrawn rearward from the hopper.

Hopper

The hopper is shown in FIGS. 1, 4, 5, 7, and 8. As shown in FIG. 7, thehopper 25 has a working position 25 a and a service position 25 b. Whenthe hopper is in the service position it is tilted 90 degrees to theright or left side to permit a person to more easily clean or servicethe hopper.

As shown in FIG. 4A, the hopper 25 has front and rear pairs of mountingarms 540, 541, 542, 543. Each mounting arm has a horizontal support pin544, 545, 546, and 547. The front mounting pins extend forwardly fromthe front mounting arms 540, 541 and the rear mounting pins extendrearward from the rear mounting arms 542, 543. The pins engage a hoppersupport 550, 551, 552, 553. Each hopper support, as best shown in FIG.8, has a U-shaped end 550 a, 550 b (not labeled for front hoppersupports). The outer end of each pin lies in the U-shaped channel of theU-shaped end. Each U-shaped end has a part of co-linear holes 550 c, 550d (labeled only for support 550) penetrating an upper portion of theU-shaped end. The co-linear holes are located above the area that thepin would occupy in the U-shaped channel. Retaining pins are removablyplaced through the co-linear holes when the support pin is in theU-shaped channel to secure the hopper to the hopper supports.

To move the hopper from the working position to the service position,each of the retaining pins on one lateral side of the machine areremoved and the hopper is tilted to the service position in thedirection opposite of the lateral side where the retaining pins wereremoved. The hopper pivots toward the side were the retaining pinsremain in place and the hopper pivots on the support pins. Likewise tomove the hopper to the working position from the service position, thehopper is tilted toward the side of the machine where the retaining pinswere removed, until the support pins on that side engage the U-shapedsupports. Then the retaining pins are secured through the co-linearholes to secure the hopper in the working position.

Food Pump System

The food pump system 300 of the machine 100 is shown in FIGS. 1, 2,12-13B, 14A-17. The pump system 300 comprises a rotary pump 330, a pumpmotor 350, a mounting bracket 302, a pump intake passage 310, and a pumpoutput passage 316.

The outlet flange 536 of the hopper outlet 532 connects to a pump intakepassage 310. A gasket may be provided between the outlet flange 536 andthe pump intake passage to seal the connection therebetween. The intakepassage 310 has a vertically narrowing passage 310 a to connect to thepump intake flange 337 which surrounding the intake opening inlet 334 ofthe food pump 330. In one embodiment, the intake has a width in thetransverse direction that is as wide as the food pump inlet 334 and thehopper outlet 532. The intake passage narrows vertically as shown inFIG. 2. The intake flange is located at a vertical position that ishigher than the vertical position of the mold plate 32.

The pump 330 is mounted and supported by a trunnion mount system 600.The trunnion mount includes a rotatable cylinder 620 that rides within afront collar support 610 and a back collar support 612. The supportcollars 610, 612 are attached to a cross member 630 that is supportedand connected to a pair of vertical frame supports 632, 634 that areattached to the machine base 21 by bolts 632 a, 634 a. The front andback supports 610, 612 have circular holes that are aligned and withinwhich the cylinder 620 is supported. The cylinder connects at the rearend to a mounting bracket 640, 644 that surrounds the gear area 332 c ofthe pump 330. The pump is connected to the bracket on at least one sideby a four bolts 642. A vertically extending support 646 is connected tothe mounting bracket and extends upward to a vertical mounting plate311.

The pump has an inlet that is located above the mold plate and themanifold 27. The pump has an outlet that is located above the mold plateand the manifold 27. To facilitate maintenance and cleaning, the pump330 and pump motor 350 are rotatable on the trunnion mount system 600between a working position as shown the location of the outlet 338 d anda maintenance position as shown by the location of the outlet 338 c inFIG. 13A. In the working position a pump output passage 316 connect anoutlet 338 of the pump to the output passage 316. In one embodiment, thepump and motor are substantially perpendicular to the mold plate when inthe working position and the pump and motor are parallel to the moldplate when in the maintenance position.

To move the pump from the working position to maintenance position, theoutput passage is disconnected from the outlet 338 of the pump, theintake passage 310 is disconnected from the flange 337 of the inlet 334of the pump, a lock mechanism (not shown) on the trunnion mount system600 is released and the pump is rotated about an axis of rotation 610 aof the trunnion system. As shown in FIG. 13a , the motor rotates indirection D and the pump outlet 338 rotates in direction E about theaxis of rotation 610 a to bring the pump and motor to the maintenanceposition. The axis of rotation 610 a is co-axial with the cylinder 620.The locking mechanism of the trunnion system may be tightened or securedto hold the pump in position. While in one embodiment the motor and pumpare substantially parallel to the mold plate when in the maintenanceposition, in other embodiment the motor and pump may be placed at anyposition about the axis of rotation 610 a wherein the motor or pump donot contact or impact other parts of the machine, such as the mold plateor mold plate drive portion. However, if portions of the mold plate ormold plate drive are removed during maintenance, then the motor and pumpmay be further rotated.

As shown in FIG. 13A, the pump output passage 316 fans out laterally ina V-shape to connect with a correspondingly wide manifold inlet 111 a.The output passage is secured to the manifold inlet 111 a by bolts 318or stud and nut combinations.

The rotary pump is shown in detail in FIGS. 14A-16. In one embodiment,the pump rotary pump is a Universal I Series Positive DisplacementRotary Pump, model number 224-UI with a rectangular outlet flangemanufactured by Waukesha Cherry-Burrell, with a place of business inDelavan, Wis., and affiliated with SPX Flow Technology. A positivedisplacement pump causes a food material to move by trapping a fixedamount of it then forcing that trapped volume into the discharge openingor pipe.

As shown in FIG. 15, the pump 330 has a housing with a pump area 332 aand a gear area 332 c. The pump has an inlet 334 and an outlet 338 incommunication with the pump area 332 a. The pump area is separated fromthe gear area by a wall 332 d. A portion of the gear area is shown inFIG. 16 were the back cover plate is removed. A drive gear 364 and adriven gear 365 are meshed across a meshed arch of each gear 356 a, 364a. The drive gear is keyed to rotate in sync with the drive shaft 360 ata first end of the drive shaft. The drive gear has a locking nut andlock washer 361 that assists in securing the gear to the drive shaft.The driven gear is keyed to rotate the driven shaft 363. The drivenshaft has a locking nut and lock washer 361 that assists in securing thegear to the driven shaft at a first end of the drive shaft. The drivenand drive shafts are journal through a support structure (not shown) inthe housing to carry rotors 340 a, 343 a at second ends of the drivenand drive shafts opposite the first ends. The support structure (notshown) in the housing contains high capacity, double tapered rollerbearings that the drive and driven shafts rotate on. The rear coverplate (not shown) contains an opening to allow the drive shaft to extendoutside of the housing to engage a drive source such as the motor 350.

The second ends of the drive and driven shafts have a splined section(not shown). The rotors 340 a 343 a have a splined opening that mateswith the splined section of the drive and driven shafts respectively.Each rotor 340 a, 343 a has two wings 340, 341 and 342, 343,respectively. The wings have overlapping areas of rotation as shown inFIG. 14E. Each wing is located opposite the other wing on the rotor andgaps are located between the wings about the circumference of the rotor.The wings travel in annular-shaped cylinders 339 c (not labeled forrotor 340 a) machined into the pump body. The rotor is placed on theshaft with a plate portion 344, 345 outwardly facing. Nuts 348, 349 arescrewed on a threaded end portion of the shafts to secure the rotor inplace. The rotors have a close fit clearance between the outer surfaceof the wing 343 a and the corresponding cylinder wall faces 339 c of thepump area. As shown in FIG. 14E, the wing of one rotor will be locatedin the open area of the other rotor during a portion of an operationcycle. An operation cycle comprises a full 360 degree rotation of arotor.

The splined mating of the rotors and shafts ensure that the rotorsrotate in sync with the respective drive and driven shafts. The rotorsare interference fitted in the pump area as shown by their overlappingareas of rotation. The meshed gearing 356 a, 364 a prevents the rotorsfrom contacting each other during operation.

When the drive shaft 360 is rotated in direction C shown in FIG. 16, thedrive shaft rotate the first rotor in the same direction, direction A inFIG. 15. Simultaneously, as provided by the meshed gearing 364, 365 thesecond rotor is rotated in the opposite direction, as shown by directionB in FIG. 15, of that of the first rotor.

The vacuum created by the rotation of the rotors 340 a, 343 a capturesand draws food product in to an inlet 334, through the pump and theoutlet passage 338 a, and out the outlet 338. The outlet may havethreads 338 b on the outside of the outlet as shown in FIG. 15.

The pump area 332 a face 339 a is covered to enclose the pump area by aface plate 332. The face plate has raised areas 332 a, 332 b foraccommodating space required for the shaft ends and the correspondingnuts 348, 349. The face has a plurality of holes corresponding to thestuds 339 that extend from the face 339 a. Face plate wing nuts 333secure the face plate to the face 339 a.

The outlet 338 is a circular outlet and the inlet 334 is an oblong witha rectangular flange 337. The rectangular flange 337 has an oval seal orgasket 336 surrounding the oblong inlet.

The outlet 334 connects pump output passage 316. The output passage 316includes an expanding-V section 316 a that connects with the manifoldinlet 111 a. The output passage 316 connected to the manifold 27 with alower hinge 318. When the output passage is connected to the rotary pump330 and the output passage is in the deployed position, a flange 317 ofthe output passage is flush with the face 319 of the manifold at theinlet passage 111. When the output passage is disconnected from therotary pump and in a lowered position 326, the flange and output passagepivots downward and away from the inlet passage about the lower hinge318.

The pump 330 is driven by the pump motor 350. The motor is shown in FIG.17. In one embodiment, the motor 350 is a servo rotary actuator, such asthe TPM+ Power 110 Stage 2 series rotary actuator with brakemanufactured by Wittenstein, Inc. with a place of business in Bartlett,Ill. In one embodiment, motor 350 is an electric servo rotary actuator,such as the model TPMP110S manufactured by Wittenstein, Inc. The servorotary actuator comprises a combined servo motor and gearbox assembly inone unit. The servo rotary actuator has a high-torque synchronous servomotor. The configuration of the servo motor and the gearbox gearingprovides the actuator with a reduced length. The actuator has ahelical-toothed precision planetary gearbox/gearhead for reduced noiseand quiet operation. The rotary actuator has a 70:1 gearing ratio, 1180ft./lbs. of torque, and maximum speed of 65 RPMs.

The motor 350 has a housing 351, an electrical connection 351 b, amounting face 315 b, and an output coupling flange 358 b. The mountingface 315 b has a plurality of holes 315 a. As shown in FIG. 2, the pumpis secured to a mounting plate by a plurality of bolts 311 a whichengaged the back of the pump, such as by engaging threaded holes 332 eat the back of the pump. The mounting plate is secured to the machinebase 21 by bolts 312. A circular mounting member 313 encloses theconnection between the motor and the pump and attaches to the mountingplate 311. Alternatively, the mounting member 313 may connect directlyto the machine base. The mounting member 313 connects to the motor 350at the mounting face. A number of bolts 315 secure the motor to themounting member. A circular coupling 356 is attached to the outputcoupling flange 358 b by bolts 358 threaded into the correspondinglythreaded holes 358 a of the output coupling flange 358 b. At an oppositeend, the coupling 356 receives the drive shaft 360 in an opening of thecoupling 356. The drive shaft 360 has a key 360 a that engages acorresponding slot of the opening of the coupling 356 to lock themachine 100 to the drive shaft of the pump. The motor is angled to alignwith the output shaft of the pump.

Molding Mechanism

As shown in FIGS. 1, 2, 9-13B, the lower surface of the housing 71 thatencloses the manifold 27 is positioned over a fill plate 121 a thatforms a flat, smooth mold plate support surface. The fill plate may besurrounded longitudinally by a guide plate (not shown) so that the fillplate is modular within the guide plate and thereby the fill plate canbe quickly and easily changed. The mold top plate 121 and the fill plate121 a may be fabricated as two plates or a single plate bolted to orotherwise fixedly mounted to the housing 71.

The housing 71, manifold 27, top plate 121, fill plate 121 a, andtrunnion mount system 600 are supported by a plate 635. The plate may beintegrated with the housing 71, so that the plate and housing are oneunitary piece. The plate is connected to four towers 632 that aresupported on the machine base 21. A stud 632 a extends from the bottomof the tower 632 into a hole in a machine base frame plate or beam 633.A nut 634 is threaded on the stud 632 a on the opposite side of the beam633. The tower 632 has a second stud 637 that extends from the upperportion of the beam 633 to be received into a hole of the plate 635. Onthe lower side of the plate 635 is a collar 636 that is secured aroundthe top of the tower 632. The collar is tightenable by a tighteningmechanism, such as a screw or bolt and nut combination.

The fill plate 121 a may include includes apertures or slots 121 e thatform a lower portion of the manifold 27. In one embodiment, theapertures or slots 121 e comprise additional smaller second fillapertures or slots 121 b such as those disclosed in U.S. Pat. No.7,255,554, which is hereby incorporated by references to the extent notinconsistent with the present description. The slots 121 b are shown forone of the slots 121 e in FIG. 9, but it is understood that the eachslot 121 e may comprise slots such as 121 e.

Mold plate 32 is supported upon a bottom plate 122. Mold plate 32includes a plurality of individual mold cavities 126 extending acrossthe width of the mold plate and alignable with the manifold outletpassageways 111 c. The mold plate may have a single row of cavities ormay have plural rows of cavities, stacked in aligned columns or instaggered columns. A breather plate or bottom plate 122 is disposedimmediately below mold plate 32, closing off the bottom of each of themold cavities 126. The bottom plate 122 is mounted on a mold base plate123. In one embodiment, the spacing between bottom plate 122 and fillplate 121 a is maintained equal to the thickness of mold plate 32 bysupport spacers (not shown) mounted upon bottom plate 122.

The bottom plate 122 provides breather holes 216 and an associated airchannel 122 a flow connected to the breather holes for allowing theexpulsion of air during filling of the mold cavities 126, 126. Thebreather holes 216 are minute air outlet holes formed in the bottomplate, in the part of the bottom plate adjacent fill slots 121 e. As thefood product is pumped into mold cavities 126, it displaces the air inthe mold cavities. The air is forced outwardly through the breatherholes 216 and the channel 122 a, escaping through the channel 122 b andupward air channel 122 c. Upward air channel 122 c and channel 122 b mayeach be connected to conduits 3010 and 3020 respectively which routesany food product back into the pump. Conduits receiving output fromchannels 122 c and 122 b may converge at any point prior to reaching thefood pump, or may converge at the inlet to the food pump. Any foodparticles small enough to pass through the breather holes 216 followthis same path back into the pump. Alternatively, food particles maypass in a similar manner back to the food product hopper. The airchannel 122 a, 122 b is connected to an upward air channel 122 c thatmay be connected to the hopper by a suitable conduit (not shown) orconnected to the pump 330 intake by a suitable conduit, such as a pipe3000 a, 3000 b, 3000 c, 3000 d (FIGS. 24a-24d ), to recycle food productthat might be expelled with the air into the air channel. The pump mayhave a low pressure on the intake side which create vacuum to draw airthrough from the cavity and through the air channel 122 a, 122 b, 122 c.

In another embodiment, the breather plate 122 and breather holes 216 maybe configured as disclosed in U.S. Pat. Nos. 6,416,314 or 7,416,753,which are hereby incorporated by reference to the extent notinconsistent with the present description. As recognized by one skilledin the art, the breather plate of U.S. Pat. Nos. 6,416,314 or 7,416,753would need to be inverted to operate in a top fill machine of thepresent application.

As best illustrated in FIGS. 3, 4A, and 5 mold plate 32 is connected todrive rods 128 alongside the housing 71 and are connected at one end toa transverse bar 129. The mold plate drive system 500 comprises thedrive rods 128, the mold plate drive motors 138, 138 d and theassociated linkages. The bar 129 is connected to the mold plate by twoconnecting links 129 a. The connecting links are secured to the bar 129by two bolts 129 b and the links 192 a are connected to the mold plateby at least one bolt 192 c.

The other end of each drive rod 128 is pivotally connected to aconnecting link 131 via a machine 100 plate 131 a and a pivot connection131 c, shown in FIG. 5. The pivot connection 131 c can include a bearing(not visible in the figures) surrounding a pin within an apertured endof the connecting link 131. The pin includes a cap, or carries athreaded nut, on each opposite end to secure the crank arm to themachine 100 plate 131 a.

Each drive rod 128 is carried within a guide tube 132 a having bearingsthat is fixed between a wall 134 and a rear support 132 b. Theconnecting links 131 are each pivotally connected to a crank arm 142 viaa pin 141 that is journaled by a bearing 141 a that is fit within an endportion of the connecting link 131. The pin crank arm 142 is fixed to,and rotates with, a circular horizontal guard plate 135. The pin 141 hasa cap, or carries a threaded nut, on each opposite end that axiallyfixes the connecting link 131 to the crank arm 142 and the circularguard plate 135. The pin 141 rotates the link on an orbit 141 c aboutthe motor output 138 a. The connecting link 131 also includes a threadedportion 131 b to finely adjust the connecting link length.

The crank arm 142 is driven by a precise position controlled servo moldplate drive motor 138. The motor is mounted vertically in the machine sothat the output 138 a rotates on a horizontal axis which is the samehorizontal axis that the circular guard plate 135 rotates about. Thecrank arm 142 is attached to the output 138 a to rotate the crank armabout the output 138 a. The motor 138 is mounted to a motor supportplate 138 b that is mounted to and supported by the machine base 21. Asshown in FIG. 7, the motor is mounted with the output 138 aperpendicular to the support plate. The motor has power and controlcables that are routed through a wiring conduit 138 c to connect thosewires to power and machine control 23. A precise position controlledservo mold plate drive motor 138 d is identical to motor 138 but ismounted on the left side of the machine to drive the drive rod 128 onthe left side of the machine as shown in FIG. 7. The mechanicalconfiguration on the left side, regarding the mold plate drive motor andrelated connection are the same as that described for the right sideabove.

The machine control 23 has instructions for maintaining the two motors138, 138 d operating in sync so that each of the right and left driverods have the same longitudinal position along their respective rangesof motion. This is necessary to ensure that both lateral sides of themold plate are in the same longitudinal position with respect to theother and they operate in a parallel reciprocation. The mold plate isreciprocated by the synchronous output both motors 138 and 138 d.

The precise position controlled motors 138, 138 d can be a 6-7.5 HPtotally enclosed fan cooled servo motor. The servo motor is providedwith two modules: a power amplifier that drives the servo motor, and aservo controller that communicates precise position information to themachine controller 23. In one embodiment, motors 138 comprise a motor138 e driving a gearbox or gear reducer 138 f by a motor driveshaft 138g as shown in FIG. 7. The motor may be model 1FK7082-7AF71 manufacturedby Siemens AG capable of 3000 RPMs and 124 in/lbs of torque. The gearboxmay be an in-line gear box such as, an Alpha TP+050 MP manufactured byWittenstein, Inc. with a place of business in Bartlett, Ill.

The controller 23 and the servo motors 138, 138 d are preferablyconfigured such that the servo motor rotates in an opposite rotarydirection every cycle, i.e., clockwise during one cycle,counterclockwise the next cycle, clockwise the next cycle, etc.

A tie bar 139 is connected between the rods 128 to ensure a parallelreciprocation of the rods 128. As the crank arms 142 rotate in oppositerotational directions, the outward centrifugal force caused by therotation of the crank arms 142 and the eccentric weight of the attachedconnecting links 131 cancels, and separation force is taken up bytension in the tie bar 139.

One circular guard plate 135 is fastened on top of each crank arm 142.The pin 141 can act as a shear pin. If the mold plate should strike ahard obstruction, the shear pin can shear by force of the crank arm 142.The guard plate 135 prevents an end of the link 131 from dropping intothe path of the crank arm 142.

FIG. 5 illustrates a proximity sensor 144 in communication with themachine control 23. A target 144 a is clamped onto output shaft 138 a ofthe gear box 138 f. The proximity sensor 144 communicates to thecontroller 23 that the crank arm 142 is at a particular rotary positioncorresponding to the mold plate 32 being at a pre-selected position.Preferably, the proximity sensor 144 can be arranged to signal to thecontroller that the crank arm 142 is in the most forward position,corresponding to the mold plate 32 being in the knockout position. Thesignal confirms to the controller that the knockout cups 33 can besafely lowered to discharge patties, without interfering with the moldplate 32.

During a molding operation, the molding mechanism 28 is assembled asshown in FIGS. 2 and 9, with bottom plate 122 tightly clamped ontospacers (not shown).

In each cycle of operation, knockout cups 33 are first withdrawn to theelevated position as shown in FIG. 9. The drive for mold plate 32 thenslides the mold plate from the full extended position to the moldfilling position with the mold cavities 126 aligned with passageway 111c.

During most of each cycle of operation of mold plate 32, the knockoutmechanism remains in the elevated position, shown in FIG. 9, withknockout cups 33 clear of mold plate 32. When mold plate 32 reaches itsextended discharge position 32 b, the knockout cups 33 are drivendownward in direction A to discharge the patties from the mold cavities.

The discharged patties may be picked up by the conveyor 460 or may beaccumulated in a stacker. If desired, the discharged patties may beinterleaved with paper, by an appropriate paper interleaving device.Such a device is disclosed in U.S. Pat. Nos. 3,952,478 or 7,159,372,both incorporated herein by reference to the extent not inconsistentwith the present description. In fact, machine 100 may be used with awide variety of secondary equipment, including steak folders, birdrollers, and other such equipment.

By using a servo motor to drive the mold plate, the mold plate motioncan be precisely controlled. The motion can have a fully programmabledwell, fill time, and advance and retract speeds as controlled by themachine control 23.

Mold Base Lift Mechanism

During mold plate change or to clean the apparatus, it is necessary tolower the mold base plate 123 from above the mold plate 32 and the fillplate 121 a. The collars 626 are loosened as a first step for loweringthe mold base plate 123.

A mold base lift mechanism 800 is mounted inside the machine base 21 andextends upward to mold base 123. The lift mechanism includes two jacks802, 804 shown in FIG. 3A. The jacks are operatively connected to rightangle drives 808, 810, which are operatively connected to a T type rightangle drive 814, via drive shafts 818, 820 and respective couplings 823,824, 826, 828, 830. The right angle drive 814 is driven into rotation bya motor 836.

The jack 802 is described below with the understanding that the jack 804is identically configured and functions identically, in tandem, as thejack 802.

As shown in FIG. 3A the drive 808 turns a threaded rod or jackscrew 842that drives a nut drive assembly 844 vertically. The jack screw 872 isjournaled for rotation at a top end by a guide 845. The jack screw 842can include a bearing therebetween for smooth journaled rotation of thejackscrew. The drive assembly 844 is operatively connected to a liftcolumn 850 via a bracket 851 which is aligned over the jackscrew. Thelift column has an opening 851 a. The bracket is connected at the columnon each side of the opening at the bottom of the column. Thereby thebracket and the jackscrew are received in a portion of the opening 815a. The columns 850 of the jacks 802, 804, have keys 815 c extending fromthe tops of the columns. The keys engage corresponding slots of the moldbase and the mold base rest on top surfaces 815 d of the columns. In oneembodiment, the columns 850 are hollow and can also serve as wire andtube conduits. The columns 850 are journaled through frame plate 633 andguides 639. Bearings may be included within the journaled areas toreduce friction from contact between the columns and the frame plate.

A sensor 908 is mounted on or adjacent to the lift mechanism forsignaling to the machine control the position of the jacks. In oneembodiment, the jacks have a corresponding reading strip on the surface804 a of the jacks that the sensor reads to provide a jack locationsignal to the machine control. The machine control may be programmed toprevent operation of the machine when jacks are in a predeterminedposition, such as a lowered position. Further a proximity sensor (notshown) is mounted at an elevated position within the machine base alongthe vertical path of the target (not shown) mounted to the jacks andsignals a pre-determined raised maximum height or depth of the mold basefor a mold plate change out procedure. The proximity sensor signals themachine controller to stop the motor 836 at that point.

In another embodiment, the lift mechanism 800 may be that disclosed inU.S. Pat. No. 7,229,277, which is herein incorporated by reference tothe extent not inconsistent with the present description.

Knockout Mechanism

Molding mechanism 28 further comprises a knockout mechanism or apparatus140 shown in FIGS. 2, 9-12. The knockout apparatus comprises theknockout plungers or cups 33, which are fixed to a carrier bar 145 bybars 145 a. Knockout cups 33 are coordinated in number and size to themold cavities 126 in the mold plate 32. One knockout cup 33 is alignedwith each mold cavity 126. The mold cavity size is somewhat greater thanthe size of an individual knockout cup.

The knockout apparatus 140 is configured to drive the carrier bar 145 intimed vertical reciprocation. The knockout apparatus includes a knockoutdrive mechanism 140 a, a knockout cup system 140 b. The knockout drivemechanism is positioned below the mold plate and at least partiallyenclosed in the machine base 21. The knockout cup system 140 b islocated about the mold plate during at least a portion of any knockoutcycle. The knockout shaft connects 147 a the knockout drive to theknockout cup system and may be considered a part of either.

FIGS. 9-12 illustrate the knockout apparatus 140 in more detail. Thecarrier bar 145 is fastened to knockout support brackets 146 a, 146 b.The knockout support brackets 146 a, 146 b are carried by two knockoutrods 147. Each knockout rod 147 is disposed within a wall of a knockouthousing 148 and is connected to a knockout beam 149. The knockout beam149 is pivotally mounted to a crank rod 151 that is pivotally connectedto a fastener pin 156 that is eccentrically connected to a crank hub 155that is driven by a knock out cup drive motor 157.

The motor 157 is preferably a precise position controlled motor, such asa servo motor. An exemplary servomotor for this application is a 3000RPM, 2.6 kW servo motor provided with a brake, such as apermanent-magnet synchronous servo motor made by Siemens AG having amodel number of 1FK7064-7AF71-1GB0. The servo motor is provided with twomodules: a power amplifier that drives the servo motor, and a servocontroller that communicates precise position information to the machinecontroller 23.

The controller 23 and the motor 157 are preferably configured such thatthe motor rotates in an opposite direction every cycle, i.e., clockwiseduring one cycle, counterclockwise the next cycle, clockwise the nextcycle, etc.

A heating element 160 surrounds, and is slightly elevated from theknockout carrier bar 145. A reflector 161 is mounted above the heatingelement 160. The heating element heats the knock out cups to apre-selected temperature, which assists in preventing food product fromsticking to the knock out cups. The heating element 160 can beconfigured as disclosed in U.S. Ser. No. 13/187,426 filed on Jul. 20,2011, and herein incorporated by reference to the extent notinconsistent with the present disclosure.

In FIGS. 10 and 11, the crank hub 155 is rotated into a position whereinthe crank rod 151 is vertically oriented and the knockout beam 149 islifted to its maximum elevation. The knockout rods are fastened to theknockout beam 149 by fasteners 152. The knockout support bracket(s) 146are in turn fastened to the knockout shafts 147 a by fasteners (notshown). The knockout shafts 147 a are connected to the knockout beam 149by fasteners such as bolts 147 c, 147 d. The knockout shafts areconnected to the knockout beam at positions outside of those where theknockout rods 147 are attached as shown in FIG. 11.

An air flap or air check valve 33 a can be provided within each cup toassist in dispensing of a meat patty from the knockout cup 33.

As shown in FIG. 10, the motor 157 is supported by a bracket 170 from asupport plate 201. The bracket 170 includes one or more slotted holes,elongated in the longitudinal direction (not shown). One or morefasteners 173 penetrate each slotted hole and adjustably fix the motor157 to the frame member. The motor 157 includes an output shaft 176 thatis keyed to a base end of the crank hub 155. The fastener pin 156retains a roller bearing 178 thereon to provide a low friction rotaryconnection between an annular base end 151 a of the crank rod 151 andthe pin 156.

The crank rod 151 has an apertured end portion 179 on an upper distalend 151 b opposite the base end 151 a. The apertured end portion 179 isheld by a fastener pin assembly 180 through its aperture to a yoke 182.The yoke 182 is fastened to the knockout beam 149 using fasteners. Thefastener pin assembly 180 can include a roller or sleeve bearing (notshown) in like fashion as that used with the fastener pin 156 to providea reduced friction pivot connection.

The housing 148 is a substantially sealed housing that provides an oilbath. Preferably, the housing walls and floor is formed as a castaluminum part. The crank hub 155, the pin 156, roller bearing 178, theapertured end portion 179, the fastener pin 180 and the yoke 182 are allcontained within the oil bath having an oil level 183. The limits of theoil bath are defined by a housing 184 having a front wall 185, a rearwall 186, side walls 187, 188, a top wall 189 and a sleeve 190. Thesleeve 190 is a square tube that surrounds a substantial portion of thecrank rod 151 and is sealed around its perimeter to the top wall 189 bya seal element 196 a. The sleeve 190 is connected to the beam 149 andpenetrates below the top wall 189. As the yoke 182 reciprocatesvertically, the beam 149 and the sleeve 190 reciprocate vertically, thesleeve 190 maintaining a sealed integrity of the oil bath. The aperturedend portion 179 connects to the knockout beam 149 at the center of theknockout beam.

The crank rod 151 includes side dished areas 151 c that act to scoop andpropel oil upward during rotation of the hub 155 to lubricate the pin180 and surrounding areas.

The knockout rods 147 are guided to reciprocate through the side walls187, 188, particularly, through upper and lower bearings 191 a, 191 b.The rods 147 are sealed to the top wall by seals 192. The bearings 191 acan include an internal groove 193 that is in flow-communication with alubricant supply through port 194.

A lubricant system 194 a is provided to provide lubricant to thebearings 191 a, 191 b. The system 194 a includes a lubricant reservoir194 b that is filled with lubricant, such as oil, and connected to plantair 194 c via an electronically controlled valve 194 d. The machinecontroller 23 periodically, according to a preset routine, actuates thevalve 194 d to propel some lubricant into the bearings 191 a. Lubricantcan run down the knockout rod 147 into a dished top 191 c of the lowerbearings 191 b to allow oil to penetrate between the knockout rods 147and the lower bearings 191 b.

As shown in FIG. 10, an outer cover 195 is fastened and sealed aroundthe side walls 187, 188 and front and rear walls 185, 186 by fasteners,spacers 196 and a seal 197. Any lubricating oil that passes through theseal can be returned to the oil bath via dished out drain areas anddrain ports through the top wall.

The front wall 185 includes an oil level sight glass 185 a, a fill port185 b (shown dashed in FIG. 10), a drain port 185 c (FIG. 11); and anaccess hole closed by a screw 185 d (FIG. 11).

The crank hub 155 is journaled for rotation by two roller bearings 198,199. The roller bearings 198, 199 are supported by a collar assembly 200bolted to the rear wall 186 and to the motor 157.

The knockout assembly is changeable to extend further forwardly tominimize knockout cup cantilever. This is accomplished by loosening thebracket 170 from the frame member 172 and sliding the motor and all theconnected parts forward or rearward and replacing circular adapterplates for the knockout rods 147.

The housing 148 is fastened to a support plate 201 by fasteners 201 a.The support plate 201 has holes 201 c that surround the bearings 191 band associated bearing assemblies 191 c. The support plate 201 isconnected to the machine base frame plate or beam 633 of the base 21, byfour upward extending support members 201 e. The support members 201 ehave threaded studs 201 f that extend downward through correspondingholes in the support plate 201. Nuts 201 g are secured to thecorresponding studs 201 f to secure the support plate 201 to the supportmembers 201 e. The support members connect to the support plate 201 ator about the four corners of the support plate.

In one embodiment there are two knockout shafts 147 a. The knockoutshafts are journaled through a guide 71 c. The guide is attached to thetop 71 e of the manifold 27 as shown in FIGS. 2 and 9. The guide hasopenings or bearing guides 71 d that the knockout shafts 147 a arejournaled through. The openings 71 d may contain bearings (not shown).The knockout shafts 147 a extend through openings in the carrier bar145.

The knockout shafts extend upwards through the machine base. Theknockout shafts extend on either side of the mold plate 32 in thelateral direction as shown in FIG. 3A. Therefore, the mold plate 32 ispositioned in between the knockout shafts 147 a when the mold platecavities are aligned with the knockout cups.

The knockout assembly is changeable to extend further forwardly tominimize knockout cup cantilever and stress in supporting members. Thisis accomplished by loosening the bracket 170 from the frame member 172and sliding the motor 157 and the connected parts forward or rearwardand replacing the circular adapter plates that guide the knockout rods147. The guide is also adjustable in its connection to the 71 manifoldto slidably move the guide forward or backward within a rangelongitudinally to adjust the location of the knockout cups in concertwith the adjustment of the knockout drive mechanism 140 a.

A proximity sensor 202 is bolted to the outer cover 195, and a target203 is provided on the crank bar 149 to be sensed by the proximitysensor 202. The proximity sensor 202 communicates to the controller 23that the knockout cups are raised and the mold plate can be retractedwithout interfering with the knockout cups.

The movement of the knockout cups is fully programmable for differentmotion profiles, including dwell, accelerations and extend and retractspeeds. Such motion profiles may be useful depending on the propertiesof the food product to be discharged from the mold plate cavities.Because both the mold plate and the knockout cups can be driven byprogrammable, controlled servo motors, they can be flexibly sequencedwithout being restricted in motion by a common mechanical system.

The hopper tilt system and the touch screen control panel 601 areconfigured such that apparatus can be easily factory converted from aright side operating apparatus to a left side operating apparatus, thatis, factory reversible across the longitudinal centerline of theapparatus.

The operation of the machine is controlled by the machine control 23.The machine control is schematically shown in FIG. 1. The machinecontrol is signal connected to the rotary pump motor 350, the feed screwdrive motors 406, 408, the mold plate drive motors 138, 138 d, sensor144, and the knock out cup drive motor 157. These connections allow themachine to control the operation of the various components of themachine. The connections allow the machine control to know the operatingstatus of each component. The machine control has computer readableinstructions for carrying out the functions and operations of thevarious parts of the machine as described above and for receiving andrecording data about the same.

The machine control 23 can be implemented as a programmed generalpurpose computer, or a single special purpose integrated circuit (e.g.,ASIC) having a main or central processor section for overall, machinecontrol, and separate sections dedicated to performing various differentspecific computations, functions and other processes under control ofthe central processor section. The machine control 23 can be implementedusing a suitably programmed general purpose computer, e.g., amicroprocessor, microcontroller or other processor device (CPU or MPU),either alone or in conjunction with one or more peripheral (e.g.,integrated circuit) data and signal processing devices. In general, anydevice or assembly of devices on which a finite state machine capable ofimplementing the procedures described or carrying out functionsdescribed herein can be used as the machine control 23.

Alternate Pump System

In an alternate embodiment, the molding machine comprises an alternatepump system 1300 connected to a fill plunger system 2000 forpressurizing the food mass as illustrated in FIG. 18. The pump system1300 and fill plunger system 2000 are together interfit between outletflange 536 of the hopper and the fill plate 121 a of the moldingapparatus, as in the previously described embodiment. The pump systemincludes the rotary pump 330 and the pump motor 350 together aspreviously described but mounted 90 degrees from the previouslydescribed embodiment to a horizontal motor-to-pump orientation (see FIG.20). The rotary pump output passage 316 channels the food mass from thepump into an alternate intake manifold 1027. The intake manifold issimilar to the manifold 27 except a truncated triangular cross-sectionblock 1027 a is bolted inside the manifold 1027 to decrease the degreeof flare or expansion of the manifold in the longitudinal direction.This is done for example for single cavity filling of ground beefproducts through a slot fill to for operational reasons to reducemanifold volume to make some products more responsive to compression orpressurizing. The pump output passage 316 is connected to the intakemanifold 1027 at the manifold inlet passage 111 a. The intake manifold1027 is enclosed within a lower housing 1071. An upper housing 1072 isdisposed above the lower housing 1071 and secured to the lower housing1071 using flange nuts and studs 1073. The manifold inlet passage 111 ais open into the upper housing 1072.

In one embodiment, the fill plunger system 2000 comprises a pair ofplungers 2010. Plungers 2010 move between a raised position and anextended position. In its raised position, the tip 2011 of the plungeris within the upper housing 1072 just above the intake manifold 1027. Inan extended position, the plunger extends into the intake manifold 1027to displace a pre-determined volume of food mass in the intake manifold.The upper housing 1072 comprises a plunger channel 1075 in communicationwith an opening 1076 into the intake manifold to allow vertical movementof the plunger through the plunger channel 1075 and into the intakemanifold. The vertical movement of the plunger 2010 into the intakemanifold 1022 varies the volume, and accordingly the pressure of thefood mass within the intake manifold. The increase in food mass pressureas a result of the displacement of the food mass in the manifold can becoordinated with the reciprocating movement of the mold plate. Forexample, pressure may be increased within the intake manifold using thefill plunger system prior to the mold cavity coming into communicationwith the intake manifold by beginning the downward stroke of theplunger, and continuing the downward stroke of the plunger into themanifold as the mold plate slides into the fill position. Various othertiming combinations of the plunger movement and the mold plate movementcan be used to achieve the desired mold cavity filling dynamic.

To ensure a secure seal between the plunger channel 1075 and the plunger2010 such that food mass does not escape from the plunger channel 1075,a seal, such as a rubber or silicone O-ring is disposed along thecircumference of the plunger channel 1075. Any other suitable seal knownto one skilled in the art can also be used.

Movement of the plungers 2010 are controlled by a linear actuator 2020.Plungers 2010 are connected to a plunger shaft 2030, which are connectedto an actuating rod 2050 (FIG. 22) as part of the linear actuator 2020.The actuators 2020 are supported on top of a platform 2021, which issecured to the lower housing 1071 by a support frame 1030 comprisingvertical supports 1031. Vertical supports 1031 each comprise an externaltube 1031 a with an internal threaded shaft 1031 b (FIG. 20). The shaftextends out opposite ends of the tube and is threaded into the lowerhousing 1071 and receives a nut 1033 on top to secure the platform 2021to the vertical supports 1031, and to the lower housing 1071.

One embodiment of the drive mechanism for the linear actuators 2020 isillustrated in FIGS. 21 and 22. Revolution of a pair of toothed drivengears 2060 disposed at the top of the pair of linear actuators 2020extends and retracts the actuating rods 2050 by an internal screw driveor other rotary-to-linear movement converter. The toothed driven gearsare driven by a toothed belt 2080, driven by a toothed driving gear2070. Toothed driving gear 2070 is connected at the center of the gearto a motor 2090, such as a servomotor. The motor drives the gear 2070which simultaneously drives both toothed driven gears 2060 such that themovement of the two plungers are in synchronization. Any other suitablemethod of driving the driving gear, such as the use of a drive belt, canalso be used.

Other means of driving the plungers can be used, such as servo-motorlinear actuators, pneumatic or hydraulic cylinders, etc.

Plungers can be any suitable size or shape, providing the desiredcross-sectional area and volume of food mass displacement, andaccordingly, the desired increase in pressure for a particular type offood mass and/or mold plate. The shape of the intake manifold opening1076 and the plunger channel 1075 are shaped accordingly to complementthe shape and size of the plungers. The extension distance of theplungers into the manifold can vary according to the desired fillpressure. The fill plunger system can be used with any type of moldplate 1090. In one embodiment, the plunger in its raised position may beraised such that the tip 2011 of the plunger is above the upper housing1072, as illustrated in FIG. 19.

In one embodiment, the plunger in its extended position extends into theupper housing 1072, but remains above the manifold.

Alternate Hopper Tilt

FIG. 25 illustrates an alternate embodiment wherein a hopper 25 istilted toward the back of the machine for cleaning. The hopper is shownin a tilted-back position and up cleaning position 25 a and a normaloperating position 25 b. The hopper is supported on the machine base bytwo laterally spaced apart pinned connections 3002 at the rear (onlyforeground one being visible in the Figure) and by two laterally spacedapart plastic pads or pucks 3004 at the front (only foreground one beingvisible in the Figure). The pinned connections and pads are arranged ina rectangular grid pattern. A pneumatic or hydraulic cylinder actuator,or other known linear actuator 3008 is used to tilt the hopper. Theactuator is shown in an extended-hopper tilt position 3008 a and aretracted-hopper in use position 3008 b.

From the foregoing, it will be observed that numerous variations andmodifications may be effected without departing from the spirit andscope of the invention. It is to be understood that no limitation withrespect to the specific apparatus illustrated herein is intended orshould be inferred.

The invention claimed is:
 1. A food product forming machine, comprising:a food supply; a rotary food pump connected to the food supply; amolding mechanism having a mold plate, the mold plate including a cavityand being reciprocated by a mold plate drive between a cavity fillposition and a cavity discharge position; a knockout drive forreciprocating a knockout plunger to discharge molded food products froma cavity in the mold plate; a manifold connected to an outlet of thefood pump and having an outlet passageway through which food mass isconfigured to pass toward the mold plate for filling the cavity of themold plate; and at least one plunger configured to extend into themanifold to increase a pressure of the food mass in the manifold,wherein the at least one plunger travels an extension distance, andwherein the extension distance of the at least one plunger is variableaccording to a desired pressure of the food mass.
 2. The machine ofclaim 1, further comprising: a hopper for holding a supply of foodproduct; an auger system configured to deliver food product from thehopper downstream toward the rotary food pump.
 3. The machine of claim2, wherein the auger system has at least one feed screw located in thehopper and a feed screw drive configured to rotate the feed screw. 4.The machine of claim 3, wherein the feed screw is located at a bottom ofthe hopper.
 5. The machine of claim 4, wherein the feed screw ispositioned horizontally in the bottom of the hopper and is configured torotate and drive food product toward a front of the hopper.
 6. Themachine of claim 3, wherein the hopper has an outlet at a front of thehopper.
 7. The machine of claim 3, wherein the hopper has an outlet thatextends from a floor of the hopper upward at a front of the hopper. 8.The machine of claim 3, wherein the hopper has a main hopper body and anoutlet that extends forward of the main hopper body.
 9. The machine ofclaim 3, wherein the hopper has an outlet that encloses a forwardportion of the feed screw.
 10. The machine of claim 3, wherein thehopper has a main hopper body and an outlet, and wherein the outlet hasa connecting section connected to the main hopper body and a narrowingsection extending from the connecting section opposite the main hopperbody.
 11. The machine of claim 3, wherein the feed screw drive islocated outside of the hopper and is axially aligned and connected witha shaft of the feed screw.
 12. The machine of claim 11, wherein theauger system has a plurality of feed screws and the feed screws areparallel to each other.
 13. The machine of claim 2, wherein the augersystem has a plurality of feed screws located in the hopper and arelocated adjacent to each other and adjacent to a floor of the hopper.14. The machine of claim 1, wherein the outlet of the manifold isconnected to an inlet of the molding mechanism.
 15. The machine of claim1, wherein the pump is a positive displacement pump.
 16. The machine ofclaim 1, wherein the pump has two rotors configured to create a vacuumbetween an inlet of the pump and the outlet of the pump when driven torotate for drawing food product to the outlet.
 17. The machine of claim1, wherein the pump has two rotors, each rotor having at least twowings, each rotor has an area of rotation that overlaps with the otherrotor.
 18. The machine of claim 17, wherein the pump has a drive shaftand a driven shaft, the drive shaft has a drive gear at a first end andone of the rotors at a second end, the driven shaft has a driven gear ata first end and the other of the rotors at a second end; the drive anddriven gears are enmeshed to operate the rotors in sync.
 19. The machineof claim 17, wherein each rotor has open areas between the wings; andwherein one of the wings of one rotor operates in one of the open areasof the other rotor during a portion of an operation cycle.
 20. Themachine of claim 1, comprising a pump motor connected to a drive shaftof the rotary pump.
 21. The machine of claim 20, wherein the pump motoris a servo rotary actuator.
 22. The machine of claim 1, wherein the atleast one plunger is a first plunger, the machine further comprising asecond plunger configured to extend into the manifold to increase apressure of the food mass in the manifold.
 23. The machine of claim 22,wherein the first plunger and the second plunger move insynchronization.
 24. The machine of claim 22, wherein the extensiondistance of the first plunger is a first extension distance, wherein thesecond plunger travels a second extension distance, and wherein thesecond extension distance of the second plunger is variable according tothe desired pressure of the food mass.
 25. The machine of claim 24,wherein the first extension distance and the second extension distanceare the same.